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Villads Haar Jakobsen, WTG Platform and Diagnostics
A brief introduction to Six Sigma - Data driven problem solving
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June 27, 2012
Agenda
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• What is it actually
• Purpose of Six Sigma
• Example of a Six Sigma project organisation
• What about all these belts?
• Different Six Sigma methodologies
• DMAIC
• DFSS
• Where could Six Sigma be used at DONG Renewables
What is it actually?
Six Sigma: A method A well defined process and tool kit used for:
Product & service improvements Design of products and services
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Six Sigma: A Metric The "six Sigma level" of a process can be used to express its capability
How well it performs with respect to customer requirements Defects per million opprotunities
Six Sigma: Symbol, value, benchmark or goal Greek letter which defines standard deviation in statistics Standard deviation is a measure for spread/variation
The average distance of the data points to the mean
Purpose of Six Sigma
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To reduce variation To work with continous improvements To reduce cost of poor quality / reliability To make decisions based on statistical basis
Release the full potential
Example of a Six Sigma project organization
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What about all these belts??
White belt For managers What can we gain from six sigma projcts How do we understand the language of six sigma
Yellow belt Know the stages in DMAIC Understanding of the 7 basic tools and some statistics
Green belt Know about the basic statistical tools used in six sigma Six Sigma project manager
Black belt High level of statistical tools used in six sigma Six sigma project manager Coaching green belts
Master black belt Extensive experience from many six sigma projects
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Different Six Sigma methodologies
Six Sigma
DMAIC DFSS
DMADV
Design MethodologyImprovement methodology
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DMAIC Process flow and objectives
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DMAIC Examples of tools
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• Problem statement• Process map• Fishone diagram• Voice of the customer• CTQ's
• Pareto• Histogram• Fishbone• SIPOC• C&E matrix• Data collection
plan• Data quality (MSA)• Capability analysis• Process stability
(control charts)
• FMEA• Histograms,
Boxplots, Multi-vari charts, main effects plots, interaction plots, etc.
• Hypothesis tests• T-tests• ANOVA
• Regression analysis
• FMEA• Pugh matrix• Project
inplementation• DoE• EVolutionary
Operations (EVOP)• Process mapping• Capability analysis
• Audit plan• SPC• Hypothesis testing
What is the project
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DDefine
Problem statement Define the goals What is the cost of the problem Who are the stakeholders What are the customer requirements
Ojective statement
How does the existing process work?
How is the process and the flow
Project charter
Baseline and capability MMeasure
What is the current performance?
Understand the process behaviour Which factors influence the output Verify the mesurement system Data collection Look for patterns Calculate the capability
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Potential root causes AAnalyze
What are the key root causes?
Identify sources of variation Determine the critical process
parameters Develop and confirm theories
using data
What possible solutions have been identified?
Models with the highest explanatory power
y = f (x1, x2, x3 . . . xn)Critical Xs
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Developement of solutions and implement
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IImprove
Implement the solution
Risk management Contingency plan
Make a pilot project and compare with initial data Implement the solution Calculate performance (capability)
Evaluate the solutions and optimize choosen solution
Which solution provides the best output for the customer Cost benefit analysis
Perhaps it is necessary with additional experiments Optmize chosen solution
Time
Quality/reliability
Cost
Sustainable solution
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CControl
How do we keep the benefits of the new solution
Optimize and refine solution Make a follow up plan for the implemented solution Monitor and control
DFSS
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• Kano/survey• Project management
tools• Project selection• Benchmarking• SIPOC• C&E matrix• CTQ matrix
• Brainstorming• FMEA screening• DoE• QFD• Benchmarking• Process map
• FMEA • Reliability
• Robustness• Risk analysis• Pareto analysis• Gap analysis
• Robust design• Taguchi
• DoE• Specification design• Work design• Machine design• Engineering design
• Reliability test• FMEA• Simulation• SPC• Control plan
Charter CTQ's Concept and design selection
Detailed product design Prototype
Examples of areas where Six Sigma could be used at DONG
Developement/implementation phase
• Choose optimum supplier / component
• Evaluation of reliability
• Quality inspection
Within warranty phase
• Concerns about the life of components
• Compare performance
Out of warranty phase
• Optimize settings
• RCA
• Improve processes
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• When working with experiments (DoE)
• RCA
• Improve processes
• Life tests – Robustness and Reliability
• RCA
• Improve processes
Questions?
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Back up – Bathtub curve and the Weibull distribution
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Normal life phase
Constant failure rate
Wear out phase
Increasing failure rate
Infant mortality
Decreasing failure rate
β < 1 β = 1 β > 3
β > 5
λ
TimeUp to "5" yrs ≈ 20 ?
RCA – Analysis of life data
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